Steel shell for use in building construction

ABSTRACT

A metal frame is provided for reinforcing a unitary concrete building having side and end walls and a gabled roof. Wall studs and a center ridge beam are first erected. The studs and beam are initially plumbed to be sure they are in proper vertical alignment. Then, roof joists are extended between the beam and the studs without disturbing alignment of the studs. A latticework is provided around the entire frame structure for supporting concrete. The interior of the frame is surfaced with a concrete supporting lath-like layer and then concrete is sprayed onto both the interior and exterior surfaces of the frame to complete a building construction.

United States Patent [151 3,659,388 Sirianni [4 May 2, 1972 [54] STEEL SHELL FOR USE IN BUILDING 2,379,636 7/1945 Hedgren ..52/74l CONSTRUCTION 3,324,611 6/1967 ....52 741 3,394,523 7/1968 ..52/250 [72] Inventor: Donald M. Sirlnnnl, 530 NW. 189 Ter- 3,462 897 8/1969 race, Mlaml, Fl 33169 3,473,285 10/1969 Reiland ..52/295 [22] Filed: Nov. 18, 1969 Primary ExaminerFrank L. Abbott [21] APPL 877,624 Assistant Examiner-Leslie A. Braun Attorney-Whittemore, Hulbert & Belknap [52] U.S. Cl ..52/91, 52/94, 52/250,

52/294, 52/295, 52/296 ABSTRACT [51] Int. Cl. ..E04b 1/41, E04b l/48 A metal frame is provided for relnforcmg a unitary concrete [58] Field ofSearch ..52/91,94, 250, 259, 2935279461, building having Side and end walls and a gabled moi wan studs and a center ridge beam are first erectedf'l'he studs and beam are initially plumbed to be sure they are in proper verti- [56] Reierences cued cal alignment. Then, roof joists are extended between the UNITED STATES PATENTS beam and the studs without disturbing alignment of the studs. A lattlcework 15 provided around the entire frame structure 3,540,177 1 H1970 for supporting concrete. The interior of the frame is surfaced 3,559,354 1 971 with a concrete supporting lath-like layer and then concrete is 3,562,979 1971 sprayed onto both the interior and exterior surfaces of the 1,293,373 2/1919 frame to complete a building construction. 1,968,045 7/1934 2,159,991 5/1939 6 Claims, 6 Drawing Figures IN VENTOR. DOA A1041. J/fi/A/V/V/ BY WM MM ATTORNEYS PATENTEDMAY 2m 3,659,388

SHEET 30F 3 INVENTOR. 50/14 140 A4. JY/P/A/V/V/ BY E %Z% TORNEYS STEEL SHELL FOR USE IN BUILDING CONSTRUCTION BACKGROUND OF THE INVENTION The high cost of erecting new buildings has had an inhibiting effect on the expanding economy. Many efforts have been made to provide building constructions which may be erected with a minimum of labor, particularly highly skilled construction labor. Concrete buildings have provided a partial solution for inexpensive building, particularly in the area of commercial sheds and storage shops. Such concrete buildings normally include a steel shell or frame which is erected on a concrete floor slab. After the frame has been erected, concrete is sprayed thereonto to form the building walls and roof. The entire process is relatively fast and efficient.

The present invention provides such structure in which the main building elements which comprise the wall studs and the center ridge beam are first erected and plumbed to be certain that they are in the proper vertical alignment. The remainder of the framework including the roof joists and latticework may be then secured in place with a minimum of highly skilled labor and with a minimum of supervisory control.

SUMMARY OF THE INVENTION A frame for reinforcing a unitary concrete building having side and end walls and a gabled roof is provided. The frame includes means forming a base. The lower ends of a plurality of spaced apart upstanding metal studs are embedded in the base around the periphery thereof to define side wall and end wall stud dowels. An upstanding metallic wall stud is secured at its lower end to each stud dowel and supported on the base to define side wall and end wall studs. Each wall stud has an outwardly extending portion at the upper end thereof. A pair of horizontally spaced apart metallic roof joist support members extend along the outwardly extending portions of the side wall studs for the length of each side wall portion. A longitudinally extending ridge beam extends centrally between the side wall studs from end-to-end of the frame. A plurality of spaced apart support columns extend between the beam and the base. The beam is positioned above the studs. A plurality of metal roof joists extend from the beam downwardly to the side wall studs and are supported at the lower ends thereof on the roof joists support members. Each roof joist extends from a point on the beam to a point between a pair of adjacent side wall studs.

IN THE DRAWINGS:

FIG. 1 is an end view in section illustrating one embodiment of an erected steel shell in the process of having concrete applied thereto in accordance with the present invention;

FIG. 2 is an elevational view on an enlarged scale illustrating a vertical wall stud mounted in place;

FIG. 3 is an elevational view of the upper portion of the roof structure illustrating the juncture of the center ridge beam, support columns and roof joists;

FIG. 4 is a view in perspective of one corner of a partially erected steel shell;

FIG. 5 is a top plan view of one end of a partially erected steel shell; and

FIG. 6 is a view in perspective of a completed building in accordance with the method of the present invention.

The structure and method of the present invention is directed towards construction of a steel reinforced unitary concrete building 10 as illustrated in FIG. 6. The building 10,

as will be noted, is a generally oblong structure being considerably longer than it is wide. Although the proportions may, of course, be modified as desired, the structure illustrated in FIG. 6 is about four times as long as it is wide 1 10 inches X 26 inches). The length may be increased as desired. However, the width of the building is preferably not increased considerably because this would entail the necessity to use considerably heavier gauge reinforcing elements than is contemplated to achieve the low cost and efficient building methods which the invention inherently possesses.

The building 10 has vertical sidewalls l2 and end walls 14. A plurality of windows 16 and doors 18 may be provided therein in accordance with the needs of the user of the building. The roof is of gable construction having equal sides 20, 22 which join in the longitudinal center of the building in a ridge 24. The sides have overhanging eaves 26, 28 which extend beyond the sidewalls 12 of the building. An eave 30 is also provided at each end of the building to overhang the end walls 14.

As will be noted in FIGS. 1, 2 and 4, the first step in constructing the building 10 comprises laying of a concrete floor slab 32 which is provided around the periphery thereof with a footing 34. A plurality of stud dowels 36 are mounted in the floor slab 32 adjacent the edges thereof. The stud dowels 36 are fabricated of steel and are relatively short members. As will be noted in FIG. 2, the lower end 38 of each dowel is embedded into the slab 32 closely adjacent to the outer edge thereof. As will be appreciated, the dowels 36 are imbedded into the slab before the slab has hardened. The dowels are plumbed so that they will be accurately vertically oriented. The dowels are spaced apart at a distance of, for example, 18 to 24 inches center-to-center. The dowels 36 adjacent the corners are positioned approximately 1% inches from the corner. This construction aids in providing firmly reinforced corner segments of the building.

After the floor slab and attached dowels have been completed and the concrete has cured, a vertical steel stud 40 is mounted at each dowel 36. As best shown in FIGS. 2 and 4, each stud 40 comprises a vertical portion 42 with an outwardly projecting portion 44 at the upper end thereof. The portion 44 makes an angle of approximately 90 with the vertical portion 42. The stud 40 is fabricated of an angle member which, for example, has legs 46, 48 of equal length such as 1% inches each and which may be of a thickness of about oneeighth inch. The lower end of each stud rests on the top surface of the floor slab 32 immediately behind the stud dowel 36. The outer surface of the leg 46 is pressed against the dowel 36 and the stud 40 temporarily secured to the dowel 36 by means of a wire wrap 50. When the stud 40 has been plum bed so that it is truly vertical, the lower end thereof may be welded to the dowel 36 for additional support.

The outwardly extending portion 44 supports a pair of steel rods 52, 54 which run the length of the side walls and the width of the end walls. A notch 56 is cut in the forward end of the legs 46, 48 for the reception of the rod 52 on the underside of the portion 44. As will be noted, when the rod 52 is received in the notch 56, it is virtually flush with the lower edge of the leg 48. The other rod 54 is secured to the top edge of the leg 48 about 4 inches from the juncture with the vertical portion 42. The rods 52, 54, which are of relatively heavy gauge steel, as for example No. 5 bars, are welded in place on the portion 44.

A longitudinally extending center ridge beam 58 is provided between the sidewall studs and elevated thereabove. The beam 58 runs from one end to the other of the floor slab 32. The beam 58 is illustratively fabricated as a steel reinforced concrete member. As will be noted in FIG. 3, the beam 58 comprises a longitudinally extending flat bar 60 which has a steel rod 62, 64, 66, 68 welded on the side thereof adjacent each comer. The rods extend for the length of the beam as does the bar 60. A steel support plate 70 is provided on the lower edge of this composite structure. As will be noted, the upper rods 62, 64 are positioned slightly below the upper edge of the bar 60. This is to accommodate the downward angle of steel roof joists 72, 74, which are welded thereto at a later stage of erection of the steel shell. The entire composite including the bar 60, rods 62, 64, 66, 68 and plate 70 has cast thereon a concrete matrix 76. As will be noted, the concrete matrix 76 has inwardly curving side surfaces 78, 80 and downwardly slanting upper surfaces 82, 84. As an alternate to the steel reinforced concrete beam structure illustrated, an all steel beam may be used.

A plurality of spaced apart vertical support columns 86 extend between the beam 58 and the floor slab 32. The columns 86 may be, for example, steel pipe 2% to 3% inches in diameter. A metal plate 88 is provided between the lower ends of the columns 86 and the floor surface. The columns 86 are spaced apart a distance of, for example, 10 to 12 feet.

After the ridge beam 58 and wall studs 40 have been mounted in place, the roof joists 72, 74 are mounted in place. The roof joists 72, 74 are of relatively heavy gauge bar stock as, for example, No. steel. Each roof joist extends from the ridge beam 58 towards the portion 44 of the studs 40 at a downward angle. The lower end of each joist passes over the rod 54 and under the rod 52 and terminates at substantially this point. The joists are welded, at the upper ends thereof, to the exposed portions of the beam rods 62, 64 and bar 60. The joists are welded at the lower ends thereof to the rods 52, 54 to result in a sturdy construction.

As will be noted in FIGS. 4 and 5, the joists 72, 74 are staggered between the studs 40, a joist being provided between each pair of studs. One advantage of the present construction is the mounting of the studs and roof joists. Once the studs have been erected in place and are plumbed, the roof joists may be easily mounted without disturbing the geometric relationship. This means that the roof joists can be mounted quickly, with reduced labor and with reduced control over the labor because it is difiicult to make a serious mistake at this point. It will be noted that the roof joists 72, 74 at the ends of the building extend from the edge of the beam 58 to intersect the abutting stud rods 52, 54 of the end and side wall portions. The lower portion 90 of the joists 72, 74' are formed outwardly to blend the eaves 26, 30 smoothly together.

After the studs, ridge beam and roof joists have been erected, a latticework-like arrangement of steel rods is applied to the roof and walls. As will be noted in FIGS. 1 and 4, a plurality of longitudinally extending spaced apart rods 92 extend from end-to-end of the'roof joists. Similar longitudinally extending spaced apart rods 94 are secured to the sidewall studs. Laterally extending spaced apart rods 96 are provided on the end walls above the end wall studs. These rods 96 extend between the end roof joists 72', 74 and are of diminishing length from bottom to top to accommodate the gabled roof structure. Relatively short rods 98 are provided intermediate each end wall stud in a manner similar to the connection of the roof joists to the side wall studs. Finally, laterally extending spaced apart rods 100 are provided on the -end walls and secured to the end wall studs. The rods 100 extend into juncture with the ends of the rods 94 on the side walls to form a comer. This juncture may be welded to provide a secure corner. As will be appreciated, all of the rods above-mentioned are welded to the various roof joists and studs to secure them in place. These rods may be of less gauge than the previously mentioned rods as, for example, No. 3 steel bars. The rods 92, 94, 96 and 100 which are applied over the roof joists, side wall studs and end wall studs are preferably spaced apart a distance of about to 16 inches.

A After the rods 92, 94, 96, 98, 100 have been secured in place, the interior surfaces of the thus erected steel shell are covered with sheets of perforate 3.4 galvanized metal 102 as illustrated in FIG. 1. All interior surfaces are so covered. The function of the sheets 102 is to act as an interior retainer for subsequently applied concrete. In place of the sheets 102, metal ribbed lath work may be employed. The laths may be, for example, inch thick. Any door framing or window framing may at this time be mounted. Then, as again noted in FIG. 1, all interior and exterior surfaces are sprayed with a coating 104, 106 of liquid concrete. The means for spraying with concrete are conventional and well known. Both the interior and exterior layers 104, 106 are sprayed to a thickness of from two to four inches. Upon setting and curing of the concrete, the building construction is basically complete. The interior thereof may be subsequently finished by use of non-structural interior partitions which may be regular rocklath and plaster walls or of dry wall construction. Wiring, plumbing and the like may be applied between the non-structural and the structural portions of the building.

What I claim as my invention is:

1. A frame for reinforcing a unitary concrete building structure having side and end walls and a gabled roof, comprising means forming a concrete base, a plurality of spaced apart upstanding metal stud dowels, said dowels being relatively short and having the lower ends thereof embedded in the base around the periphery thereof prior to the hardening of the concrete todefine side wall and end wall stud dowels, an upstanding metallic wall stud secured at the lower end thereof to each stud dowel after the concrete has hardened thus defining side wall and end wall studs, the lower end surface of each wall stud abutting said base, each wall stud having an outwardly extending horizontal portion at the upper end thereof, a pair of horizontally spaced apart metallic roof joist support members extending along said outwardly extending portions of the side wall studs for the length of each side wall portion, a longitudinally extending ridge beam extending centrally between the side wall studs from end-to-end of the frame, a plurality of spaced apart support columns extending between the beam and the base, said beam being positioned above the studs, a plurality of metal roof joists extending from the beam downwardly to the side wall studs and supported at the lower ends thereof on the roof joist support members, each roof joist extending from a point on the beam to a point between a pair of adjacent side wall studs, a plurality of spaced apart metallic latticework rods extending from end-to-end of the roof joists, from end-toend of the side wall studs, and from side-to-side of the end wall studs, all of said rods being located on the exterior surface of the frame, a pair of horizontally spaced apart metallic support members extending along said outwardly extending portions of the end wall studs for the width of each end wall portion, and additional support elements extending from said rods intermediate each adjacent pair of end wall studs.

2. A frame as defined in claim 1, and further characterized in that said ridge beam includes a metallic surface on the upper portion thereof, said roof joists being welded to said metallic surface.

3. A frame as defined in claim 2, and further characterized in that said ridge beam comprises a concrete matrix reinforced with a longitudinally extending metallic structure, a portion of said metallic structure being exposed at the upper section of the beam to define said metallic surface.

4. A frame as defined in claim 1, and further characterized in that the side wall stud and end wall stud at each corner of the frame are placed closely adjacent each other, the end roof joists extending between the juncture of the roof joist support members and metallic support members, respectively, and welded thereto to define an integrated comer.

5. A frame as defined in claim 1, and further characterized in that one of said roof joist support members is located adjacent the outer end of the outwardly extending portion of the side wall studs and positioned on the underside thereof, the other of said roof joists support members being located adjacent the juncture of the outwardly extending portion of the side wall studs and the side wall stud proper, said roof joists extending over said other roof joist support member and under said one roof joist support member.

6. A frame for reinforcing a unitary concrete building structure having side and end walls and a gabled roof, comprising means forming a concrete base, a plurality of spaced apart upstanding metal stud dowels, said dowels being relatively short and having the lower ends thereof embedded in the base around the periphery thereof prior to the hardening of the concrete to define side wall and end wall stud dowels, an upstanding metallic wall stud secured at the lower end thereof to each stud dowel after the concrete has hardened thus defining side wall and end wall studs, the lower end surface of each wall stud abutting said base, each wall stud having an outwardly extending horizontal portion at the upper end thereof, a pair of horizontally spaced apart metallic roof joist support members extending along said outwardly extending portions of the side wall studs for the length of each side wall portion, a longitudinally extending ridge beam extending centrally between the side wall studs from end-to-end of the frame, a plurality of spaced apart support columns extending between the beam and the base, said beam being positioned above the studs, a plurality of metal roof joists extending from the beam downwardly to the side wall studs and supported at the lower ends thereof on the roof joist support members, each roof joist extending from a point on the beam to a point between a pair of adjacent side wall studs, a plurality of spaced apart metallic latticework rods extending from end-to-end of the roof joists, from end-to-end of the side wall studs, and from side-to-side of the end wall studs, all of said rods being located on the exterior surface of the frame, a pair of horizontally spaced apart metallic support members extending along said outwardly extending portions of the end wall studs for the width of each end wall portion, additional support elements extending from said rods intermediate each adjacent pair of end wall studs,

said ridge beam including a metallic surface on the upper portion thereof and a concrete matrix reinforced with a longitudinally extending metallic structure, a portion of said metallic structure being exposed at the upper section of the beam to define said metallic surface, said roof joists being welded to said metallic surface, the side wall stud and end wall stud at each comer of the frame being placed closely adjacent each other, the end roof joists extending between the juncture of the roof joist support members and metallic support members, respectively, and welded thereto to define an integrated corner, and one of said roof joist support members being located adjacent the outer end of the outwardly extending portion of the side wall studs and positioned on the underside thereof, the other of said roof joists support members being located adjacent the juncture of the outwardly extending portion of the side wall studs and the side wall stud proper, said roof joists extending over said other roof joist support member and under said one roof joist support member.

* III II UNITED STATES PATENT OFFICE CERTEFICATE F CORRECTIN Patent No. 3 I 659 I 388 Dat d May 2, 1972 Inventoflx) Donald M Sirianni It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

On sheet 4, insert the following in Column 1 under the inventor's name:

(73) Assignee: P-Squared, Inc.

Signed and sealed this 3rd day of October- 1972.

(SEAL) Attest:

EDWARD MQFLETCHER,JR-

Commissioner of Patents FORM FO-IOSO (10-69) USCOMM-DC 60376-P59 Q U S. GOVERNMENT PRINTING OFFICE I969 O366334 

1. A frame for reinforcing a unitary concrete building structure having side and end walls and a gabled roof, comprising means forming a concrete base, a plurality of spaced apart upstanding metal stud dowels, said dowels being relatively short and having the lower ends thereof embedded in the base around the periphery thereof prior to the hardening of the concrete to define side wall and end wall stud dowels, an upstanding metallic wall stud secured at the lower end thereof to each stud dowel after the concrete has hardened thus defining side wall and end wall studs, the lower end surface of each wall stud abutting said base, each wall stud having an outwardly extending horizontal portion at the upper end thereof, a pair of horizontally spaced apart metallic roof joist support members extending along said outwardly extending portions of the side wall studs for the length of each side wall portion, a longitudinally extending ridge beam extending centrally between the side wall studs from end-to-end of the frame, a plurality of spaced apart support columns extending between the beam and the base, said beam being positioned above the studs, a plurality of metal roof joists extending from the beam downwardly to the side wall studs and supported at the lower ends thereof on the roof joist support members, each roof joist extending from a point on the beam to a point between a pair of adjacent side wall studs, a plurality of spaced apart metallic latticework rods extending from end-to-end of the roof joists, from end-to-end of the side wall studs, and from side-to-side of the end wall studs, all of said rods being located on the exterior Surface of the frame, a pair of horizontally spaced apart metallic support members extending along said outwardly extending portions of the end wall studs for the width of each end wall portion, and additional support elements extending from said rods intermediate each adjacent pair of end wall studs.
 2. A frame as defined in claim 1, and further characterized in that said ridge beam includes a metallic surface on the upper portion thereof, said roof joists being welded to said metallic surface.
 3. A frame as defined in claim 2, and further characterized in that said ridge beam comprises a concrete matrix reinforced with a longitudinally extending metallic structure, a portion of said metallic structure being exposed at the upper section of the beam to define said metallic surface.
 4. A frame as defined in claim 1, and further characterized in that the side wall stud and end wall stud at each corner of the frame are placed closely adjacent each other, the end roof joists extending between the juncture of the roof joist support members and metallic support members, respectively, and welded thereto to define an integrated corner.
 5. A frame as defined in claim 1, and further characterized in that one of said roof joist support members is located adjacent the outer end of the outwardly extending portion of the side wall studs and positioned on the underside thereof, the other of said roof joists support members being located adjacent the juncture of the outwardly extending portion of the side wall studs and the side wall stud proper, said roof joists extending over said other roof joist support member and under said one roof joist support member.
 6. A frame for reinforcing a unitary concrete building structure having side and end walls and a gabled roof, comprising means forming a concrete base, a plurality of spaced apart upstanding metal stud dowels, said dowels being relatively short and having the lower ends thereof embedded in the base around the periphery thereof prior to the hardening of the concrete to define side wall and end wall stud dowels, an upstanding metallic wall stud secured at the lower end thereof to each stud dowel after the concrete has hardened thus defining side wall and end wall studs, the lower end surface of each wall stud abutting said base, each wall stud having an outwardly extending horizontal portion at the upper end thereof, a pair of horizontally spaced apart metallic roof joist support members extending along said outwardly extending portions of the side wall studs for the length of each side wall portion, a longitudinally extending ridge beam extending centrally between the side wall studs from end-to-end of the frame, a plurality of spaced apart support columns extending between the beam and the base, said beam being positioned above the studs, a plurality of metal roof joists extending from the beam downwardly to the side wall studs and supported at the lower ends thereof on the roof joist support members, each roof joist extending from a point on the beam to a point between a pair of adjacent side wall studs, a plurality of spaced apart metallic latticework rods extending from end-to-end of the roof joists, from end-to-end of the side wall studs, and from side-to-side of the end wall studs, all of said rods being located on the exterior surface of the frame, a pair of horizontally spaced apart metallic support members extending along said outwardly extending portions of the end wall studs for the width of each end wall portion, additional support elements extending from said rods intermediate each adjacent pair of end wall studs, said ridge beam including a metallic surface on the upper portion thereof and a concrete matrix reinforced with a longitudinally extending metallic structure, a portion of said metallic structure being exposed at the upper section of the beam to define said metallic surface, said roof joists being welded to said metallic surface, the side wall stud and end wall stud at each corner of the framE being placed closely adjacent each other, the end roof joists extending between the juncture of the roof joist support members and metallic support members, respectively, and welded thereto to define an integrated corner, and one of said roof joist support members being located adjacent the outer end of the outwardly extending portion of the side wall studs and positioned on the underside thereof, the other of said roof joists support members being located adjacent the juncture of the outwardly extending portion of the side wall studs and the side wall stud proper, said roof joists extending over said other roof joist support member and under said one roof joist support member. 